Pipeline Corrosion Identification and Prevention

Oil and Gas Technology October 25, 2025
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Introduction

This technical course provides a deep dive into the mechanisms, identification, and control of corrosion, the single largest threat to pipeline integrity. It covers both internal corrosion (due to H2S, CO2, water) and external corrosion (due to soil, stray current), detailing the principles of cathodic protection (CP) and protective coatings. Participants will learn how to use corrosion monitoring tools, interpret inspection data, and design effective prevention programs to ensure the long-term fitness-for-service of pipeline infrastructure. The course is essential for maintaining asset integrity, complying with regulations, and preventing catastrophic failures.

Objectives

Upon completion of this course, participants will be able to:

  • Identify the primary mechanisms and forms of internal and external pipeline corrosion.
  • Explain the principles and application of impressed current and galvanic cathodic protection (CP) systems.
  • Detail the standards and procedures for inspecting and repairing external pipe coatings.
  • Design and implement chemical inhibition programs for internal corrosion control (e.g., corrosion inhibitors).
  • Interpret data from corrosion monitoring techniques (e.g., coupons, probes, intelligent pigs).
  • Troubleshoot common CP system failures and perform routine CP surveys (e.g., close interval survey).
  • Apply regulatory standards (e.g., NACE/AMPP, API, PHMSA) to pipeline corrosion management.

Target Audience

  • Pipeline Integrity and Corrosion Engineers.
  • CP Technicians and Survey Personnel.
  • Pipeline Maintenance and Operations Staff.
  • Process Engineers dealing with corrosive fluid compositions.
  • HSE and Regulatory Compliance Specialists.
  • Consultants specializing in asset integrity.

Methodology

  • Case Studies: Analyzing corrosion-related pipeline failures and the role of CP/coating breakdown.
  • Group Activities: Designing a simple cathodic protection system for a pipeline segment.
  • Individual Exercises: Calculating corrosion rates based on coupon data and predicting remaining life.
  • Discussions on the selection of optimal internal corrosion inhibitors for different fluids.
  • Scenarios: Troubleshooting a low potential reading during a routine CP survey.

Personal Impact

  • Gain high-level, specialized expertise in pipeline integrity and corrosion control.
  • Develop robust skills for identifying, mitigating, and monitoring all forms of corrosion.
  • Enhance ability to design and troubleshoot complex cathodic protection systems.
  • Increase personal value as a critical asset protection and risk management expert.
  • Master the interpretation of advanced corrosion inspection data (ILI).
  • Position for certification in corrosion control (e.g., NACE/AMPP certifications).

Organizational Impact

  • Significant reduction in pipeline leaks, ruptures, and catastrophic failures.
  • Extended asset life and minimized premature replacement of pipeline segments.
  • Improved regulatory compliance, avoiding fines and operational restrictions.
  • Lower operating costs through optimized chemical injection and CP maintenance.
  • Enhanced safety and environmental protection through robust integrity assurance.
  • Data-driven decision-making for proactive integrity management planning.

Course Outline

Unit 1: Fundamentals of Corrosion and its Impact

Section 1.1: Corrosion Theory
  • Electrochemical principles of corrosion (anode, cathode, electrolyte, metallic path).
  • Classification of corrosion types: General, pitting, stress corrosion cracking (SCC), etc.
  • The major economic, safety, and environmental impact of pipeline corrosion.
  • Understanding corrosive agents in oil and gas (H2S, CO2, water, microbes).

Unit 2: External Corrosion Prevention: Coatings and CP

Section 2.1: Protective Systems
  • Types, selection, and application standards for external pipeline coatings (FBE, coal tar enamel, tape wraps).
  • Detailed principles of cathodic protection (CP) and the difference between galvanic and impressed current.
  • Design parameters for a CP system (current requirement, rectifier placement, anode materials).
  • Troubleshooting CP systems: Interference, shielding, and measurement errors.

Unit 3: Internal Corrosion Identification and Mitigation

Section 3.1: Internal Control
  • Mechanisms of internal corrosion: Sweet (CO2), Sour (H2S), and Microbiologically Influenced Corrosion (MIC).
  • Design and optimization of chemical inhibition programs (corrosion inhibitors, biocides).
  • The role of pigging (cleaning and inhibition) in internal corrosion control.
  • Techniques for water removal and control to minimize internal corrosion risk.

Unit 4: Corrosion Monitoring and Inspection Techniques

Section 4.1: Data Collection
  • Use of corrosion coupons, electrical resistance probes, and hydrogen probes for monitoring.
  • Detailed interpretation of In-Line Inspection (ILI) data (metal loss, pitting depth).
  • Non-Destructive Examination (NDE) techniques: UT, Radiography, and visual inspection.
  • Integrity assessment methods: Remaining strength calculations (e.g., ASME B31G).

Unit 5: Corrosion Management Program and Compliance

Section 5.1: Program Management
  • Developing a comprehensive Pipeline Corrosion Management Plan.
  • Executing and interpreting Close Interval Surveys (CIS) and Direct Current Voltage Gradient (DCVG) surveys.
  • Compliance requirements for corrosion control and monitoring (e.g., NACE/AMPP SP0502).
  • Best practices for coating repair, anomaly assessment, and mitigation.

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